Pillow dispensing system for product packaging

Abstract

An apparatus for dispensing pillows for use in packaging is provided, the pillows being arranged in a web and having relatively thicker portions bordered by relatively thinner portions adjacent individual pillows in the web. The system can include a transport unit having a push member configured to engage the web of pillows as the push member moves, drawing the web into the transport unit and moving the web through the transport unit toward an exit opening of the transport unit. The apparatus can further include a separation unit having a cutting device and a movable cover at least partially enclosing the cutting device to prevent unintentional contact with the cutting device.

Description

[Background technology]

[0001] Inflated cushions, or air pillows, are a type of pillow widely used in product packaging. For example, air pillows are often used as protective packaging in a manner similar to, or in place of, foam peanuts, rolled paper, and similar products. As another example, air pillows can be used as protective packaging in place of molded or extruded packaging members. A typical type of air pillow is formed from a film having two layers joined together by a seal. The seal can be formed to trap air inside upon inflation of the pillow, or it can be formed to define a film structure with an inflatable chamber before inflation. The inflatable chamber can be inflated with air or other gas and then sealed to inhibit or prevent the release of the air or gas.

[0002] Air pillows are typically formed as a continuous web of air pillows, with each air pillow joined to an adjacent air pillow by its webbing, i.e., the non-inflatable portion at the edge of the inflatable portion. One or more individual air pillows can be separated from the web and placed within the packaging when the items to be protected by the air pillows are loaded. The air pillows can be separated from the web by cutting, tearing, or otherwise separating the webbing between adjacent air pillows, leaving the inflatable portions of the air pillows intact.

[0003] In some applications, the web may be fed directly from the equipment that generates it. In other applications, the web may be transported to a storage (holding) bin for temporary storage and then dispensed from the storage bin as air pillows are needed. Transporting the web using automated equipment can pose challenges because inflated air pillows can be punctured or otherwise damaged if not handled properly. For example, the transport equipment may damage the air pillows when the webbing becomes jammed. Also, the transport equipment may be unable to move the web if one or more pillows are fully or partially deflated due to a leak, manufacturing defect, or other damage. Furthermore, in applications where automated equipment is used to cut or otherwise separate individual pillows from the web, it can be difficult to align the webbing with the cutting equipment so that the cut is made on the webbing and not the inflated pillow. Summary of the Invention

[0004] In one aspect of the disclosed technology, an apparatus is provided for dispensing pillows for product packaging. Each cushion pillow includes a first portion and a second portion having a thickness less than that of the first portion. The second portions of adjacent pillows abut each other to form a continuous web of pillows. The web defines peaks that coincide with the locations of maximum thickness of the first portions and valleys located between the peaks.

[0005] The apparatus includes a transport unit having at least one pressing member configured to engage the web of pillows such that the pressing member draws the web of pillows into the transport unit and moves the web of pillows through the transport unit toward an exit opening of the transport unit, the pressing member being angled away from a rotational direction of the pressing member.

[0006] In another aspect of the disclosed technique, the pressing member includes a vane.

[0007] In another aspect of the disclosed technique, the device further includes a plurality of pressing members.

[0008] In another aspect of the disclosed technique, the transport unit further includes a hub, the pressing member mounted on the hub, the pressing member extending substantially tangentially to an outer surface of the hub.

[0009] In another aspect of the disclosed technique, the transport unit further includes a guide configured to guide the web of pillows along the path.

[0010] In another aspect of the disclosed technique, a front side of the pressing member is configured to contact and advance the pillow, the front side of the pressing member being inclined at a first angle relative to an adjacent portion of the guide, and the rear side of the pressing member being inclined at a second angle relative to the adjacent portion of the guide that is a supplement to the first angle, the first angle being smaller than the second angle.

[0011] In another aspect of the disclosed technology, the guide includes a curved portion configured to guide the web of pillows along a curved path and a vertical portion adjacent the curved portion configured to guide the web of pillows to the exit opening.

[0012] In another aspect of the disclosed technique, the guide interferes with the pushing member as the pushing member moves past the guide.

[0013] In another aspect of the disclosed technique, the biasing member is configured to bend in response to interference between the biasing member and the guide.

[0014] In another aspect of the disclosed technique, the pressing member and the guide are configured such that the second portion of the pillow is caught between the tip of the pressing member and the guide when the pressing member moves past the guide.

[0015] In another aspect of the disclosed technique, the spacing between the tips of adjacent pressing members is approximately equal to the length of the pillow.

[0016] In another aspect of the disclosed technology, the guide is a second guide, the conveying (distribution) unit further includes a first guide, the first guide and the second guide are configured to guide the web of pillows toward the pressing member, the first guide and the second guide are spaced apart to ensure that the web of pillows is properly engaged within the conveying unit, and the second guide is configured as a ramp that lifts the web of pillows as it is guided along the path.

[0017] In another aspect of the disclosed technology, the pressing member is configured to advance the web of pillows in a first direction, and the dispensing unit further includes an anti-return mechanism configured to inhibit movement of the web of pillows in a second direction opposite the first direction.

[0018] In another aspect of the disclosed technique, the anti-backup mechanism includes a brush.

[0019] In another aspect of the disclosed technique, the dispensing unit further includes a wiper configured to contact the pillow and separate the pillow from the pressing member as the pressing member and pillow rotate past the wiper.

[0020] In another aspect of the disclosed technique, the wiper includes a brush.

[0021] In another aspect of the disclosed technique, the apparatus further includes a storage bin, wherein the pressing member is configured to engage the web of pillows as the pressing member rotates, such that the pressing member draws the web of pillows from the storage bin into the transfer unit.

[0022] In another aspect of the disclosed technique, the transfer unit is configured to be mounted onto and removed from the storage bin as a modular unit.

[0023] In another aspect of the present disclosure, an apparatus for dispensing pillows for product packaging is provided. Each cushion pillow includes a first portion and a plurality of second portions having a thickness less than that of the first portion. The second portions of adjacent pillows are joined to form a continuous web of pillows. The web defines peaks corresponding to the maximum thickness of the first portions and valleys located between the peaks.

[0024] The apparatus includes a separating unit configured to receive a web of packages. The separating unit includes an anvil, a cover mounted on the anvil and configured to move relative to the anvil between a first position and a second position, and a press movable between the first position and the second position. The apparatus also includes a cutting device mounted on the anvil and configured to cut the second portion of the pillow upon contacting the second portion. The cover is configured to at least partially enclose the cutting device when the cover is in the cover's first position, to move the cover from the cover's first position to the cover's second position and to push the webbing into the cutting device when the press moves from the cover's first position to the cover's second position, and to at least partially enclose the cutting device when the cover is in the cover's second position.

[0025] In another aspect of the present disclosure, an apparatus for dispensing pillows for product packaging is provided. Each cushion pillow includes a first portion and a plurality of second portions having a thickness less than that of the first portion. The second portions of adjacent pillows are joined to form a continuous web of pillows. The web defines peaks corresponding to the maximum thickness of the first portions and valleys located between the peaks.

[0026] The apparatus includes a storage bin defining an interior volume configured to receive the web of pillows, a duct defining a channel configured to receive the web of pillows and guide the web of pillows into the interior volume of the storage bin in a first direction, and an air circulation device in fluid communication with the channel and configured, during operation, to introduce air into the channel at a pressure and flow rate sufficient to move the web of packages in the first direction, and an anti-backup mechanism mounted within the channel and configured to inhibit movement of the web of pillows in a second direction opposite the first direction. [Brief explanation of the drawings]

[0027] The following drawings illustrate certain embodiments of the present disclosure and are not intended to limit the scope of the disclosure. The drawings are not to scale and are intended to be used in conjunction with the explanations in the following detailed description. Embodiments of the present disclosure are described below in conjunction with the accompanying drawings, in which like numerals refer to like elements.

[0028] [Figure 1] FIG. 1 is a side view of an air pillow dispensing system showing the string of air pillows dispensed into the system from an inflation and sealing device, showing individual strings (threads, strings) of air pillows dispensed by the system and packaged in containers, and showing the side wall of the storage bin of the system removed for clarity of illustration. [Figure 2] 2 is an enlarged view of a portion of FIG. 1, showing a supply unit of the system shown in FIG. 1; [Figure 3] FIG. 3 is a top perspective view of the distribution unit shown in FIG. 2. [Figure 4] 2 is a top view of the storage bin of the system shown in FIG. 1 with the top of the storage bin removed for clarity of illustration. [Figure 5] FIG. 2 is an enlarged view of another portion of FIG. 1. [Figure 6] 2 is a side view of the cutting device of the system shown in FIG. 1, showing the pressure bar of the cutting device in the retracted position and the cover of the cutting device in the safe position. [Figure 7] 7 is a side view of the cutting device shown in FIG. 6, showing the pressure bar moving from the retracted position toward the extended position, and showing the cover in the safe position. [Figure 8] FIG. 8 is a side view of the cutting device shown in FIGS. 6 and 7, showing the pressure bar moving from the retracted position further towards the extended position and the cover being in a safe position when the pressure bar first contacts the cover. [Figure 9] FIG. 9 is a side view of the cutting device shown in FIGS. 6 to 8, showing the pressure bar in the extended position and the cover in the retracted position. [Figure 10] 10 is an enlarged view of a portion of FIG. 9, further illustrating the webbing of the series of air pillows contacting the cutting wire of the separating device shown in FIGS. 6-9. FIG. [Figure 11] FIG. 11 is an enlarged view of the area indicated in FIG. 10 showing the webbing after it has been cut by the cutting wire. [Figure 12] 12 is a top rear perspective view of the cutting device shown in FIGS. 6-11, showing the pressure bar in its retracted position, the cover in a safe position, and the locking arm of the cutting device in a locked position. FIG. [Figure 13] FIG. 13 is a top rear perspective view of the cutting device shown in FIGS. 6-12, showing the pressure bar moving from the retracted position toward the extended position, the cover in the safe position, and the locking arm in the locked position. [Figure 14] FIG. 14 is a top rear perspective view of the cutting device shown in FIGS. 6 to 13, showing the pressure bar moving from the retracted position toward the extended position, the cover in the safe position, and the locking arm moving from the locked position to the unlocked position. [Figure 15] FIG. 15 is a top rear perspective view of the cutting device shown in FIGS. 6 to 14, showing the pressure bar moving from the retracted position further toward the extended position, the cover in a safe position when the pressure bar first contacts the cover, and the locking arm in an unlocked position. [Figure 16]16 is a top rear perspective view of the cutting device shown in FIGS. 6-15, showing the pressure bar in the extended position, the cover in the retracted position, and the locking arm in the unlocked position. FIG. [Figure 17] FIG. 3 is an enlarged view of a part of FIG. 2. [Figure 18] FIG. 3 is an enlarged view of a part of FIG. 2. DETAILED DESCRIPTION OF THE INVENTION

[0029] In the following description, conventional features of the disclosed technology that would be apparent to one skilled in the art are omitted or only briefly described. Reference to various embodiments does not limit the scope of the appended claims. Moreover, the examples described herein are not limiting, but merely present some of the many possible embodiments that correspond to the appended claims. In addition, specific features described herein can be used in combination with other features described in all possible combinations and permutations. Those skilled in the art, familiar with the present invention, will understand, through routine experimentation, how to use the present invention to achieve other results not explicitly described in the examples or embodiments.

[0030] Unless expressly defined otherwise, all terms in this specification are intended to be interpreted in the broadest sense, including the meaning implied by the specification, the meaning understood by those skilled in the art, and the meaning defined in dictionaries, specialized texts, etc. Unless otherwise defined, all technical and scientific terms used in this specification have the same meaning as commonly understood by those skilled in the art. Furthermore, as used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless otherwise specified. Furthermore, the terms "includes" and / or "including" as used herein indicate the presence of stated features, elements, and / or components, but do not exclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. Furthermore, methods, devices, and materials similar or equivalent to those described herein may be used in the practice or testing of the disclosed technology.

[0031] Various examples of the disclosed technology are provided throughout this specification. The use of these examples is merely illustrative and does not limit in any way the scope or meaning of the invention or any embodiment. Likewise, the invention is not limited to the specific preferred embodiments described herein. Indeed, modifications and variations of the invention may become apparent to those skilled in the art upon reading this specification, and these may be made without departing from the spirit and scope of the invention. Therefore, the invention is to be limited only by the language of the claims, along with the full scope of equivalents to which such claims are entitled.

[0032] Certain relationships between suppressor features are described herein using the terms "substantially" or "substantially equal." As used herein, the terms "substantially" and "substantially equal" indicate that an equivalent relationship is not an exact relationship and does not exclude functionally similar variations therefrom. Unless the context or description indicates otherwise, when the terms "substantially" or "substantially equal" are used herein in connection with two or more dimensions, it means that an equivalent relationship between the dimensions includes variations that do not change the least significant digit based on mathematical and engineering principles accepted by those skilled in the art (e.g., rounding, measurement error or other systematic errors, manufacturing tolerances, etc.). As used herein, the term "substantially parallel" means that a parallel relationship is not an exact relationship and does not exclude functionally similar variations. As used herein, the term "substantially orthogonal" similarly means that an orthogonal relationship is not an exact relationship and does not exclude functionally similar variations.

[0033] An apparatus 10 for dispensing pillows (e.g., air pillows 20) for product packaging is disclosed. Referring to Figures 1-3, the pillows 20 are supplied to the system 10 as a continuous web 22 of interconnected pillows 20. Each pillow 20 includes a relatively thick (i.e., inflated) portion 23 and relatively thin portions, or webbings 24, disposed adjacent to each other on either side of the inflated portion 23. The inflated portions 23 are filled with a fluid, such as air, and are sealed by the corresponding webbings 24 to prevent leakage of the fluid. The inflated portions 23 form the relatively thick portions of the pillow 20, and the webbings 24 form the relatively thin portions of the pillow 20. The webbings 24 function as hinges that allow adjacent pillows 20 to rotate relative to one another. The webbings 24 of adjacent pillows 20 are joined to one another, thereby forming a continuous chain 22 of air pillows 20. In certain applications, the webbing 24 may include perforations to facilitate separation, such as by tearing, of adjacent pillows 20. The relatively thick inflated portions 23 and the relatively thin webbing 24 define depressions or valleys 25 between the inflated portions 23 of adjacent pillows 20. The longitudinal midpoints of the inflated portions define peaks 27, or locations of maximum thickness, in the chains 22. (As used herein, the "longitudinal direction" of the pillows 20 corresponds to the longitudinal direction of the web 22, i.e., the direction in which the web 22 and pillows 20 are dispensed through the apparatus 10.)

[0034] Each pillow 20 may be configured, for example, to have a length dimension of approximately 4 inches when uninflated (deflated) and a length dimension of approximately 3 inches when inflated. Each pillow 20 may have a lateral dimension of approximately 8 inches when uninflated (deflated) and a lateral dimension of approximately 7 inches when inflated. Each pillow 20 may have a maximum thickness of approximately 1-5 / 16 inches when inflated, for example. These dimensions of the pillows 20 are provided for illustrative purposes only. The device 10 may be configured for use with pillows 20 having dimensions and dimension ratios smaller or larger than those stated above.

[0035] The chain 22 of pillows 20 may be produced by a pillow expanding and sealing apparatus, such as the expanding and sealing apparatus 8 disclosed in U.S. Pat. No. 11,577,484, the entire contents of which are incorporated herein by reference. Figure 1 shows the pillow expanding and sealing apparatus 8 feeding the chain of air pillows 20 directly into the apparatus 10. The pillow chain 22 may alternatively be produced by other types of apparatus and systems.

[0036] In another embodiment, the chain 22 is stored (held) before being fed to the apparatus 10. It may be directed towards a bin or other temporary storage means.

[0037] Other embodiments of the pillow 20 need not be inflated or formed from an inflatable material. For example, the web of non-inflatable pillows may be formed from one or more layers of paper or other material, with the paper configured to define an interior space within each pillow. Each interior space may be filled with padding or other material to provide cushioning and / or insulation. In this embodiment, the filled spaces form relatively thick portions of the web, and the unfilled portions of the web joining adjacent pillows form thinner portions of the web. In other embodiments, the web may comprise a continuous series of mailing envelopes. In some of these embodiments, the web may comprise a continuous series of enclosed envelopes (packaging material), with the enclosed portions forming the relatively thick portions and the top and bottom seals of each envelope forming the relatively thin portions. In other embodiments, the web may comprise a sheet or pad having relatively thick or thin portions (e.g., a foam pad, an insulating pad, or a cold chain material with compressed areas, such as fold lines, to form the sheet or pad), configured, for example, to cover the interior of a box or other packaging container. The thicker and thinner portions in these embodiments may function in a manner similar to the expanding portions 23 and webbing 24 of the web 22 .

[0038] 1, the apparatus 10 includes a storage or accumulation bin 12, a distribution or conveying (distribution) unit 14, and a separation unit 16. The accumulation bin 12 receives inflated pillows 20 from the inflation and sealing device 8. As the pillows 20 enter the apparatus 10, they are arranged in a chain 22 with adjacent pillows 20 connected by webbing 24. The pillows 20 are fed into the bin 12 and accumulated.

[0039] As shown in FIG. 1 , the expansion and sealing device 8 is positioned upstream of the accumulation bin 12 relative to the direction of travel of the chain 22. The expansion and sealing device 8 may be positioned at a first height relative to the accumulation bin 12 so that the chain 22 exits the expansion and sealing device 8 below the bottom 38 of the accumulation bin 12. Locating the expansion and sealing device 8 at the first height allows an operator better access to the chain 22 or roll of preformed chain material 610. This arrangement between the expansion and sealing device 8 and the accumulation bin 12 also provides sufficient space for the chain 22 to be fed into the accumulation bin 12 without tangling or interference. Additionally or alternatively, a conveyor 152 may be positioned below the accumulation bin 12, and in some embodiments below the transfer (distribution) unit 14, at a second height relative to the accumulation bin 12 to assist in transferring the chain 22 from the accumulation bin 12 to the packaging container 150.

[0040] The chain 22 retracts into the transport unit 14, which dispenses one or more pillows 20 in response to an operator manually actuating the transport unit 14 using a foot pedal (not shown) or other actuation means. The number of pillows 20 dispensed at one time is determined by the amount of time the operator holds down the foot pedal. Additionally or alternatively, the transport unit 14 may be configured to automatically dispense a predetermined number of pillows 20 at a time. For example, the transport unit 14 may be configured to dispense a specific number of pillows 20 in response to input from an external system, such as an automated packaging machine having void detection capabilities, i.e., the ability to detect and / or quantify voids or empty volume within a package that needs to be filled with pillows 20.

[0041] After the pillows 20 are dispensed, a separation unit 16 separates or severs the relatively short string of dispensed pillows 20 from the remainder of the chain 22 .

[0042] 1, 3, and 4, the accumulation (storage) bin 12 includes a first side wall 30 and a second side wall 32. The bin 12 also includes a front wall 34 and a rear wall 36 connected to the first and second side walls 30, 32 via a frame 37 of the bin 12. As shown in FIG. 4, the first and second side walls 30, 32 have substantially the same length. The front wall 34 and the rear wall 36 also have substantially the same length. The lengths of the front wall 34 and the rear wall 36 are shorter than the lengths of the first and second side walls 30, 32, giving the bin 12 a generally rectangular shape when viewed from above, i.e., from the perspective of FIG. 4.

[0043] The storage bin 12 further includes a bottom 38 and a top 39. The bottom 38 and top 39 are respectively connected to the first and second side walls 30, 32 and the front and rear walls 34, 36 via a frame 37. The first and second side walls 30, 32, the front and rear walls 34, 36, the bottom 38 and the top 39 define an interior space 40 of the bin 12. The interior space 40 receives the chain 22 of pillows 20. The first and second side walls 30, 32, the front and rear walls 34, 36, the bottom 38 and the top 39 may be formed from a transparent or translucent material so that the pillows 20 in the interior space 40 are visible from outside the bin 12.

[0044] As shown in Figure 4, the first and second side walls 30, 32 are spaced apart a distance approximately equal to the maximum width 19, i.e., the left-to-right dimension, of the pillow 20. The chain 22 of the pillow 20 is fed into the interior space 40 in a direction generally parallel to the first and second side walls 30, 32, such that the side or outer edge of each pillow 20 is positioned directly adjacent to either the first or second side wall 30, 32, as shown in Figure 4. Because the first and second side walls 30, 32 are spaced apart a distance approximately equal to the maximum width 19 of the pillow 20, the first and second side walls 30, 32 restrict the pillow 20 from lateral movement, i.e., from side to side, or from twisting about the longitudinal axis of the chain 22, as the chain 22 is drawn through the interior space 40 of the bin 12.

[0045] 1, 3, and 4, the apparatus 10 also includes a three-sided duct 42 attached to the exterior surface of the front wall 34. The duct 42 includes a side panel 44 and two end panels 46 adjacent to and extending perpendicular to opposite sides of the side panel 44. The duct 42 and the underlying surface of the front wall 34 define a vertically extending channel 48, shown in FIGS. 1 and 3. The lower end of the channel 48 receives the chain 22 of pillows 20 from the inflation and sealing device 8, as shown in FIG. 1. The duct 42 may be attached independently of the accumulation bin 12 in alternative embodiments.

[0046] Apparatus 10 further includes an air circulation device 50 in the form of a fan or blower attached to duct 42 and positioned near the lower end of duct 42. Air circulation device 50 is shown in FIG. 3. Air circulation device 50 is in fluid communication with channel 48 and provides an upward airflow within channel 48. The upward airflow entrains pillow 20 within channel 48 and moves chain 22 upward within channel 48. The airflow generated by air circulation device 50 is indicated in FIG. 1 by arrows 51.

[0047] Channel 48 may have a cross-sectional profile that substantially matches the height, i.e., thickness, of pillow 20 and the maximum width 19 of pillow 20, thereby preventing pillow 20 from rotating or twisting while being conveyed upward through channel 48.

[0048] 1 and 5, duct 42 includes an anti-backflow mechanism that allows pillow chain 22 of pillow 20 to move upward within channel 48 while preventing pillow chain 22 from falling downward due to gravity (i.e., in the opposite direction from the direction in which chain 22 is fed into storage bin 12) when air circulation device 50 is not operating. The anti-backflow mechanism may be, for example, an upwardly sloping plastic tab 52 that is flexible enough to allow pillow 20 to pass over tab 52 as it moves upward within channel 48, but rigid enough to support pillow chain 22 when air circulation device 50 is not pushing chain 22 upward. In alternative embodiments, the anti-backflow mechanism may be a brush, reed, or other type of device having the characteristics described above.

[0049] 1, the front wall 34 of the storage bin 12 has a lip 54 formed at its upper end. The front wall 34 is shorter, i.e., has a smaller vertical dimension, than the first and second side walls 30, 32 of the storage bin 12. The lip 54, the first and second side walls 30, 32, and the top 39 define an opening 56 adjacent to the channel 48. When the pillow 20 reaches the top of the channel 48, it passes through the opening 56 and enters the interior space 40 of the storage bin 12.

[0050] Once inside the interior space, the pillows 20 can fall downward due to gravity. As described above, because the first and second sidewalls 30, 32 are spaced apart at a distance approximately equal to the maximum width 19 of the pillows 20, the first and second sidewalls 30, 32 restrain the pillows from twisting or rotating about the longitudinal axis of the chains 22 of the pillows 20. Because each pillow 20 is connected to an adjacent pillow 20 by the webbing 24, each pillow 20 can rotate relative to the adjacent pillow 20 about a transverse axis passing through its corresponding webbing 24. Thus, the chains 22 of the pillows 20 can reverse direction as they settle into the storage bin 12. Typically, the chains 22 fall randomly and may form a series of circular S-shapes as the pillows 20 fill the interior space 40. The lateral or widthwise constraint applied to the chain 22 by the first and second side walls 30, 32 of the bin 12 prevents the chain 22 from twisting or tangling, or from assuming a position or orientation that would interfere with smooth feeding into the transport unit 14.

[0051] The apparatus 10 further includes a sensor 56 configured to detect the level of pillows 20 in the storage bin 12. The sensor is shown in FIG. 1. The sensor 56 may be, for example, an optical sensor. Alternatively, other types of sensors may be used. The sensor 56 is communicatively coupled to a control unit 58 of the apparatus 10. The control unit 58 is configured to activate the air circulation device 50 when the sensor 56 indicates that the level of pillows 20 is below a predetermined threshold (e.g., below the line of sight of the sensor 56). Activation of the air circulation device 50 supplies additional pillows 20 to the interior space 40 of the storage bin 12 in the manner described above. The control unit 58 deactivates the air circulation device 50 when it receives a signal from the sensor 56 indicating that the level of pillows 20 has reached the predetermined threshold.

[0052] Alternatively, or in addition, the device 10 may be configured to allow an operator to manually turn the air circulation device 50 on and off, and may allow an operator to manually adjust the level of the pillow 20 within the bin 12.

[0053] The transport unit 14 is attached to the storage bin 12 as shown in FIG. 1. The transport unit 14 has a modular configuration that allows it to be installed and removed from the storage bin 12 as an integrated cartridge or unit. With reference to FIGS. 1 and 3, the transport unit 14 includes a first side panel (not shown), a second side panel 61, a rotating structure in the form of a paddle wheel 62, and a motor 64. The first and second side panels 61 are securely attached to the frame 37 of the storage bin 12 near the bottom end of the storage bin 12, with the first side panel positioned adjacent to the first side wall 30 and the second side panel 61 positioned adjacent to the second side wall 32.

[0054] The control unit 58 is mounted on the outward facing side of the second side panel 61, as shown in Figure 3. The first and second side panels 61 are spaced apart from each other by a distance approximately equal to the distance between the first and second side walls 30, 32, i.e., a distance approximately equal to the maximum width 19 of the pillow 20.

[0055] The motor 64 is securely attached to the inwardly facing surface of the second side panel 61 and is located within the interior space 40 of the bin 12, as shown in Figure 3. The paddle wheel 62 is rotatably attached to a shaft (not shown), which is securely attached to the inwardly facing surface of the second side panel 61.

[0056] Motor 64 is a servo motor. In alternative embodiments, other types of motors, such as a stepper motor, may be used. Motor 64 drives paddle wheel 62 to rotate by transmitting torque from motor 64 to paddle wheel 60 via a drive belt (not shown) or other suitable device.

[0057] 2 and 3, the paddle wheel 62 includes a hub in the form of a drum 70. The paddle wheel 62 also includes six pressing members in the form of paddles or vanes 72 that are securely attached to the drum 70. The drum 70 is attached to a support shaft via bearings (not shown), allowing the drum 70 to rotate relative to the shaft. The paddle wheel 62 is connected to a drive belt via a pulley (not shown) that is securely attached to the end of the drum 70. In alternative embodiments, the hub may be configured as an axle or other structure configured to support and store the vanes 72, and the rotating structure may be configured differently from the paddle wheel 62. In other alternative embodiments, the vanes 72 may be directly connected to each other without a hub.

[0058] The vanes 72 are configured to move the chains 22 of the pillows 20 by engaging with the pillows 20 via valleys 25 formed between the expansion portions 23 of adjacent pillows 20. More specifically, each vane 72 engages with the webbing 24 between the pillows 20 and pushes against the expansion portions 23 of the pillows 20 located upstream of the vanes 72 as the paddle wheel 62 rotates.

[0059] The vanes 72 are mounted to the drum 70 such that each vane 72 extends tangentially from its mounting location on the outer surface of the drum 70, as shown in Figure 2. Thus, each vane 72 is offset approximately 90 degrees from normal to its mounting location on the outer surface of the drum 70, thereby tilting the vanes 72 away from the direction of rotation of the paddlewheel 62. As shown in Figure 17, the forward side of each vane 72 is angled at an angle 202 relative to the second portion 84 of the second guide 78, and the aft side of each vane 72 is angled at a supplementary angle 200 relative to the second portion 84 of the second guide 78, where angle 202 is less than angle 200.

[0060] 2 in alternative embodiments. For example, the vanes 72 may extend normal to the adjacent surface of the drum 70 in alternative embodiments. In other alternative embodiments, the vanes 72 may extend at an angle between an angle relative to the normal and an angle relative to the tangential direction relative to the adjacent surface of the drum 70.

[0061] The paddle wheel 62 includes six vanes 72, which is an illustrative example. The optimal number of vanes 72 may vary depending on factors such as the distance between adjacent webbings 24 in the chain 22 of the pillow 20 and whether the vanes 72 engage every webbing 24 of the chain 22, or every third webbing 24, etc. Accordingly, alternative embodiments may include fewer or more than six vanes 72.

[0062] In alternative embodiments, the pushing members may have a different configuration than the vanes 72. For example, the pushing members may be configured as rods, reeds, brushes, wires, or other structures capable of pushing against the pillow chain 22 as described herein without damaging the pillow 20 or webbing 24.

[0063] 2 and 3, the transport unit 14 further includes a first guide 76 and a second guide 78. The first and second guides 76, 78 are secured to the first and second side panels 60, 61 by mounts 79 extending between the first and second side panels 60, 61. The first and second guides 76, 78 guide the pillow chain 22 toward and around the paddle wheel 62 and out of the transport unit 14. The first and second guides 76, 78 may be formed from a flexible plastic material. In alternative embodiments, the first and second guides 76, 78 may be formed from other materials.

[0064] The first guide 76 is located near the bottom of the transport unit 14 and is configured as a ramp that lifts the chain 22 of the pillow 20 as the chain 22 approaches the paddle wheel 62, thereby helping to ensure that the chain 22 is properly positioned to properly engage or wrap around the paddle wheel 62.

[0065] The second guide 78 has a first portion 80 that surrounds the motor 64 of the transport unit 14, thereby preventing contact between the chain 22 and the motor 64. The first portion 80 also serves to guide the chain 22 of the pillow 20 as it approaches the paddle wheel 62. More specifically, the first portion 80 is spaced apart from the first guide 76, and the first portion 80 and the first guide 76 define a path or channel 82 that vertically restrains the pillow 20, thereby ensuring proper engagement between the chain 22 and the paddle wheel 62 as the chain 22 approaches the paddle wheel 62. The channel 82 is shown in FIG. 2.

[0066] The second guide 78 has a second portion 84 adjacent to the first portion 80. The second portion 84 extends over and around the paddle wheel 62 and then extends substantially vertically downward. The second portion 84 has a curved portion configured to urge the pillow 20 inward toward the rotational centerline of the paddle wheel 62, thereby maintaining the pillow 20 in contact with the rotating paddle wheel 62. As shown in FIGS. 2 and 3, the second portion 84 also includes a vertical portion that directs the pillow chain 22 to an exit opening 86 at the bottom of the transport unit 14 after the chain 22 has been conveyed around the paddle wheel 62.

[0067] The length of each vane 72 is selected so that interference occurs between the second portion 84 of the second guide and the vane 72 as the vane 72 rotates past the second portion 84 (see FIG. 2). The vane 72 may be formed from a material, such as plastic, that allows the vane 72 to bend in response to this interference and is flexible and soft enough not to damage the webbing 24 when the tip of the vane 72 comes into contact with the webbing 24 and the webbing 24 becomes entangled between the outer end or tip of the vane 72 and the second portion 84 of the second guide 78.

[0068] As described above, the pillow chain 22 is fed into the storage bin 12 through the channel 48 and accumulated in a random or semi-random folded configuration, with twisting or rotation of the chain 22 about its centerline prevented by the constraining of the pillow chain 20 by the first and second side walls 30, 32. During startup of the apparatus 10, an operator manually feeds the leading pillow chain 20 of the pillow chain 22 through the channel 82 defined in the transport unit 14 and introduces it between the vanes 72 of the paddle wheel located immediately downstream of the channel 82. Operator access to the pillow chain 22 and paddle wheel 62 is provided by an access opening and access door 90 in the first and second side walls 30, 32, as shown in FIG. 3 with respect to the second side wall 32.

[0069] A random or semi-random folding configuration can maintain the structural arrangement of the pillow chains 22. For example, as shown in FIG. 1, the majority of the pillow chains 22 fall into the storage bin 12 in even layers with lengths approximately equal to the distance between the front wall 34 and the rear wall 36. This structural arrangement prevents the pillow chains 22 from wrinkling, twisting, tangling, knotting, or entanglement. Furthermore, the even layers ensure that the height of the pillow chains 22 increases at a relatively predictable rate and in a manner that facilitates programming, for example, to dispense a predetermined number of pillows. This structural arrangement reduces system downtime by eliminating the need to shut down the pillow inflation and sealing device 8 to unwind the pillow chains 22.

[0070] During the feeding and loading process, an operator may press a “load” button (not shown) or other input device communicatively connected to control unit 58. The load button generates an input that, when received by control unit 58, causes control unit 58 to activate motor 64 and slowly rotate paddlewheel 62, thereby enabling at least the leading pillow 20 to be grasped by paddlewheel 62. The operator does not need to index pillow 20 to paddlewheel 62 during the feeding and loading process because paddlewheel 62 naturally establishes a sequence by the spacing between vanes 72 during the loading process and maintains a one-to-one correspondence between vanes 72 and pillow 20 throughout operation of apparatus 10.

[0071] As described above, the device 10 can be activated by an operator depressing a foot pedal or other input device, or upon receiving an external command requesting the dispensing of a predetermined number of pillows 20. Upon activation, the device 10 sends an input to the motor 64, which runs at normal speed. The motor 64, via a drive belt, rotates the paddlewheel 62, which rotates clockwise as viewed from the perspective of FIGS. 1-3. A vane 72 located downstream of, or behind, the leading pillow 20 pushes against the inflation portion 23 of the leading pillow 20, causing the leading pillow 20 to rotate with the paddlewheel 62.

[0072] Additionally, the adjacent downstream vane 72 engages the webbing 24 immediately aft, or downstream, of the leading pillow 20. As previously described, the length of the vane 72 and the spacing between the drum 70 and the second guide 78 are configured to allow the vane 72 to flex as it drags the webbing 24 along the adjacent surface of the second guide 78. For example, the material, flexibility, length, or a combination thereof, of the vane 72 may create a friction-like force between the tip of the vane 72 and the webbing 24 (the webbing 24 is sandwiched between the tip of the vane 72 and the second guide 78), allowing the vane 72 to drag the webbing 24 in the direction of rotation of the vane 72. The positive contact between the vane 72 and the webbing 24 and the drag force applied to the webbing 24 causes the pillow chain 22 to rotate with the paddlewheel 62. Additionally, the dragging (pulling) of the webbing 24 by the vanes 72 helps the paddlewheel 62 transport the chain 22 even when one or more pillows 20 are fully or partially deflated, flat, or otherwise defective, such that the vanes 72 are unable to push against the inflated portions 23 of the pillows 20 and thus are unable to push against a particular pillow 20. In the disclosed embodiment, it is believed that the dragging action of the vanes 72 described above and the ability of the paddlewheel 62 to simultaneously handle five pillows 20 allows the paddlewheel 62 to continue transporting the chain 22 even when three or more consecutive pillows 20 are not properly inflated, for example, when the pillows are ruptured or not fully inflated. (The force exerted by the vanes 72 against properly inflated pillows in the distribution unit 14 also helps advance the chain 22 when one or more pillows 20 are not properly inflated.)

[0073] Alternate embodiments of the transport unit 14 may be configured to handle more or fewer than five pillows 20 at a time. Additionally, the vanes 72 may be configured to have sufficient flexibility so that if the chains 22 of a pillow 20 become jammed and unable to pass through the transport unit 14, the vanes 72 can pass through the pillows in the transport unit 14 without damaging the pillow 20. The optimal flexibility of the vanes 76 depends on the stiffness of the pillow 20, which varies with factors such as the inflation pressure of the pillow 20 and the material from which the pillow 20 is made.

[0074] As the pillow chain 22 rotates in response to the rotation of the paddle wheel 62, the next or second pillow 20 in the chain 22 contacts the paddle wheel 62 (if the second pillow 20 was not already contacting the paddle wheel 62 during the loading process). In particular, the spacing between the vanes 72 is such that the next pillow 20 is retracted between the vane 72 immediately behind the leading pillow 20 and the vane 72 adjacent and downstream from that vane 72. The two adjacent vanes 72 between which the second pillow 20 is sandwiched also contact the webbing 24 immediately upstream and downstream of the second pillow 20. This retraction of the vanes 72 for subsequent pillows 20 in the chain 22 continues as the paddle wheel 62 rotates and continues to pull additional pillows 20 from the storage bin 12, thereby automatically indexing the position of the pillows 20 relative to the vanes 72, as shown in FIG. 2. In alternative embodiments, the number and spacing of vanes 72 on drum 70 may be varied to accommodate two or more pillows 20 between adjacent vanes 72 .

[0075] In the transfer unit 14, the spacing between the tips of the vanes 76 can be approximately equal to the length of the pillows 20. In alternative embodiments that can accommodate more than one pillow 20 between adjacent vanes 76, the spacing between the vane tips can be approximately equal to the total length of the pillows. The spacing between the vane tips can also be a function of the thickness of the pillows 20. For example, the maximum thickness of the pillows 20 can be approximately equal to about 50% of the spacing between the vane tips. In other embodiments, this percentage can range from about 10% to about 80%. The maximum thickness of the pillows 20 should be large enough relative to the spacing between the vane tips to allow the vanes 76 to flex as they engage the pillows 20, but not so large that the pillows become jammed between adjacent vanes 72. The spacing between the vane tips can vary from these values ​​in other embodiments.

[0076] The interaction of the individual vanes 76 with the web 22 depends in part on the physical properties of the web 22. For example, a relatively stiff or inflexible pillow 20, or a relatively heavy pillow 20, may require the vanes 76 to have a relatively low degree of flexibility, which helps ensure that the vanes 76 apply sufficient force against the pillow 20 to advance the web 22 and prevent the vanes 76 from passing through or jumping over the pillow 20. Conversely, a relatively flexible pillow 20 may require the vanes 76 to have a relatively high degree of flexibility, which helps ensure that the vanes 76 can bend sufficiently to prevent them from puncturing or otherwise damaging the pillow 20.

[0077] Additionally, a relatively thick and flexible pillow 20 may require greater flexibility of the vanes 76 or an increased angle of the vanes 76 relative to their direction of rotation, which helps increase the contact area between the vanes 76 and the pillow 20, so that the force exerted by the vanes 76 on the pillow 20 is distributed over a larger area on the pillow.

[0078] The paddle wheel 62 continues to pull or draw the accumulated pillow chain 22 from the interior space 40 of the storage bin 12. The first guide 76 and the first portion 80 of the second guide 78 guide the chain 22 to the paddle wheel 62. The aforementioned restraint of the pillow 20 by the first and second side walls 30, 31 helps ensure that the chain 22 is fed to the paddle wheel 62 without tangling or jamming.

[0079] 2, the pillow 20 is guided along a curved path and maintained in contact with the paddle wheel 62 by the arcuate portion of the second section 84 of the guide 78. The chain 22 of the pillow 20 eventually reaches the vertical portion of the second section 84, at which point the chain 22 moves downward. The chain 22 then exits the transfer unit 14 through the exit opening 86. When the operator releases the foot pedal or when the predetermined number of pillows 20 have been dispensed from the dispensing unit 14, the control unit 58 stops the motor 64.

[0080] The apparatus 10 further includes a wiper that assists in separating the pillow 20 from an adjacent vane 72 if the pillow 20 sticks or otherwise adheres to the vane 72. The wiper may be, for example, a brush 88, as shown in FIG. 2. The brush 88 is attached to the first or second side panel 60, 61 adjacent the outlet opening 86. The brush 88 extends upward, with its upwardly facing bristles contacting each vane 72 as the vane 72 rotates past the brush 88. The brush 88 is angled toward the downstream direction, i.e., the direction of movement of the chain 22. The brush 88, including its bristles, is configured to be sufficiently rigid to prevent the pillow 20 from moving with the vane 72 if the pillow 20 does not separate from the vane 72 as the vane 72 approaches the outlet opening 86 and begins to rotate upstream away from the outlet opening 86. The brush 88 is also flexible enough not to damage the pillow 20. In other embodiments, the anti-stick device may be a tab, lead, or other device having the above-described properties.

[0081] The apparatus 10 also includes an anti-reverse mechanism that prevents the pillow chain 22 from moving upstream (i.e., in the opposite direction from the direction in which the chain 22 is fed through the conveying unit 14) and away from the paddle wheel 62 after the motor 64 has stopped and the paddle wheel 62 is no longer pulling the chain 22 of the pillow 20 downstream. The anti-reverse mechanism may be, for example, a brush 90 that is angled upward and downstream and attached to the first or second side panel 61 immediately upstream of the first guide 76, as shown in FIG. 2 . The brush 90 is configured, including its upward-facing bristles, to be flexible enough to allow the pillow 20 to pass through the brush 90 as it moves downstream toward the paddle wheel 62, yet rigid enough to prevent the chain 22 from moving upstream when the paddle wheel 62 is not rotating. In alternative embodiments, the anti-reverse feature may be a tab, reed, or other device having the characteristics described above.

[0082] In alternative embodiments of the apparatus 10, the transport unit 14 may be configured to move the web 22 in a linear or other non-rotational manner. In such embodiments, the rotating structure of the transport unit 14, e.g., the paddle wheels 62, may be replaced with structure that moves the web 22 in a linear or other non-rotational direction.

[0083] The separating unit 16 is located immediately downstream of the exit opening 86 and automatically separates the dispensed string of pillows 20 from the remainder of the chain 22. Alternative embodiments of the apparatus 10 may be configured without the separating unit 16.

[0084] In embodiments without the separating unit 16, an operator can manually tear the separated string of pillows 20 from the remaining chain 22. The webbing 24 of the chain 22 used in such embodiments may include perforations to facilitate tearing without deflating or damaging the inflated portions 23 of adjacent pillows 20. The vanes 72 of the paddlewheel 26 are reverse-angled, so that the vane 72 contacting the particular webbing 24 to be torn is angled away from (against) the direction in which the operator pulls the chain 24 to tear the webbing 24. Thus, a pulling force moves the tip of that particular vane 72 toward the underlying webbing 24 and the surface of the second guide 82. The friction between the vane 72, webbing 24, and second guide 82, combined with the deactivated motor 64, creates a braking or ratcheting force that holds the paddlewheel 62 and the reeled webbing 24 in place and allows the webbing 24 to be torn along the perforations in the webbing 24. This allows an operator to quickly and easily retrieve the rows of dispensed pillows 20, even in embodiments without a separation unit 16.

[0085] The separation unit 16 automatically separates the string of pillows 20 from the remainder of the chain 22 of pillows 20 after the string has been dispensed. The separation unit 16 is mounted directly below the transport unit 14, as shown in Figures 2 and 3, so that the pillows 20 can pass through the separation unit 16 as they leave the transport unit 14 through the exit opening 86.

[0086] 6 to 16, the separation unit 16 includes a press in the form of an actuator 100 and a pressure bar 102 connected to the actuator 100. The actuator 100 may be, for example, a pneumatic actuator. The actuator 100 is configured to linearly move the pressure bar 102 between a first (or retracted) position shown in Figures 6 and 12 and a second (or extended) position shown in Figures 9 and 16.

[0087] The separation unit 16 also includes a protective element in the form of an anvil 104 and a guard or cover 108. The cover 108 is attached to the anvil 104 and configured to be linearly movable relative to the anvil 104 between a first, safe position shown in Figures 6-8 and 12-15 and a second, retracted position shown in Figures 9 and 16. The cover 108 is biased to the safe position by a spring (not shown).

[0088] The separating unit 16 further includes a cutting device in the form of a hot or cutting wire 110, as shown in Figures 10 and 11. The cutting wire 110 is attached to the anvil 104. In operation, the cutting wire 110 generates heat and cuts the webbing 24 of the pillow chain 22 when the webbing 24 contacts the cutting wire 110, as shown in Figure 10. In other embodiments, other types of cutting devices, such as a flat film heater, may be used in place of the cutting wire 110. In yet another alternative embodiment, the cutting device may be a sharp blade.

[0089] As shown in Figures 3, 4, and 7 to 9, the separation unit 16 also includes a lower guard 140 including a movable part 142 and a fixed part 144. The movable part 142 is connected to the actuator 100 and moves linearly together with the actuator 100 and the pressure bar 102. The fixed part 144 is connected to the frame 37 and is able to slide relative to the fixed part 144 when the movable part 142 moves linearly (see Figures 7 to 9).

[0090] When the pressure bar 102 and the cover 108 are in their respective retracted positions, the pressure bar 102 is spaced apart from the cover 108, and the pressure bar 102 and the cover 108 define an opening 111 (see FIG. 12). The opening 111 is aligned with the outlet opening 68 of the conveying (distribution) unit 14, so that the string of pillows 20 dispensed from the conveying unit 14 passes through the opening 111 as it exits the conveying unit 14. (The string of pillows 20 is shown in FIG. 6, but is not shown in FIGS. 7-10 for clarity.) By moving from the retracted position to the extended position, the pressure bar 102 pushes the particular webbing 24 to be cut onto the cutting wire 110, as shown in FIG. 10. This causes the webbing 24 to be cut by the heated cutting wire 110, as shown in FIG. 11. 10, the restraint of the webbing 24 by the U-shaped member 116 and cover 108 of the pressure member 102 may result in the webbing 24 stretching slightly before being cut. The separation unit 16 may include a fan (not shown) or other means to help ventilate fumes and odors that may be generated by heating the webbing 24.

[0091] The control unit 58 is configured to operate the motor 56 of the dispensing unit 14 to rotate the paddle wheel 62 a specific angle depending on the number of pillows 20 to be dispensed (dispensed). For example, the paddle wheel 62 may be rotated approximately 60 degrees to dispense one pillow, approximately 120 degrees to dispense two pillows, approximately 180 degrees for three pillows 20, etc.

[0092] The transport unit 14 includes means to help ensure that the particular webbing 24 to be cut is aligned with the pressure bar 102 and cutting wire 110. For example, the transport unit 14 includes six magnets 112 mounted at equally spaced angular increments on the side of the drum 70 of the paddle wheel 62. The magnets are shown in FIG. 2. The transport unit 14 also includes a magnetic switch (not shown) that generates an output when aligned with any of the magnets 112. The magnets 112 and magnetic sensor are positioned such that when any of the magnets 112 is aligned with the magnetic switch, the webbing 24 of the pillow chain 22 is aligned with the pressure bar 102 and cutting wire 110, as shown in FIGS. 2 and 10. Thus, the magnet 112 and magnetic switch act as an indexing means for aligning the angular position of the paddle wheel 62 with the position of the pressure bar 102 and cutoff wire 110 at the start of a dispensing cycle so that the particular webbing 24 to be cut will be aligned with the pressure bar 102 and cutoff wire 110 when the paddle wheel 62 has dispensed the desired number of pillows 20. Software within the controller 58 can also assist in aiming the webbing 24 by allowing the operator to adjust a "home offset" parameter via the control interface with the controller 58.

[0093] Control unit 58 includes a "home" switch that, when pressed by an operator, causes motor 64 of transport unit 14 to slowly rotate paddlewheel 62 until one of magnets 112 aligns with a magnetic sensor. Control unit 58, magnet 112, and magnetic switch thus function as a servo control system that allows an operator to position paddlewheel 62 in a "home position" and return it to the home position. The home or re-home operation can be performed if the angular position of paddlewheel 62 at start-up of machine 10 or the beginning of a dispensing cycle has shifted from the proper index position.

[0094] The cover 108 defines a narrow channel 113, as shown in FIGS. 10 and 11 . As shown in FIGS. 6-8 , the cutting wire 110 is positioned within the channel 113 when the cover 108 is in the safety position, such that the cutting wire 110 is surrounded on three sides by the cover 108. When the cover 108 surrounds the channel 113, the likelihood of an operator coming into contact with the cutting wire 110 is extremely low. Thus, the cover 108 functions as a safety device to minimize the possibility of an operator or others accidentally coming into contact with the heated cutting wire 110. As shown in FIGS. 9-11 , when the cover 108 is moved to the retracted position, the cover 108 no longer covers the cutting wire 110, allowing the cutting wire 110 to sever the webbing 24 when it comes into contact with the cutting wire 110. FIGS. 10 and 11 illustrate the states immediately before and after the webbing 24 is severed by the cutting wire 110, respectively.

[0095] The pressure bar 102 includes a body 114 and a U-shaped member 116. The U-shaped member 116 is attached to the body 114 and positioned to face the cutting wire 110 and the cover 108. As shown in FIG. 10 , the U-shaped member 116 is configured to contact the front, or exposed, end of the cover 108 above and below the channel 113 when the pressure bar 102 moves to its extended position. As the pressure bar 102 moves further toward its extended position, the U-shaped member 116 pushes the spring-biased cover 108 toward its retracted position. When the pressure bar 102 reaches the extended position shown in FIGS. 9 , 10 , and 15 , the U-shaped member 116 moves the cover 108 to its fully retracted position and straddles the cutting wire 110. Thus, even though the cover 108 has been retracted from the cutting wire 110, the cutting wire 110 is still covered by the U-shaped member 116 at this time, protecting the operator from accidentally coming into contact with the cutting wire 110.

[0096] 12-16, separation unit 16 also includes two control elements, for example in the form of locking arms 120 attached to either side of cover 108. A first end of each arm 120 is coupled to cover 108 such that arm 120 is pivotable between a first (or locked) position shown in Figures 12 and 13 and a second (or unlocked) position shown in Figures 15 and 16.

[0097] Each arm 120 defines a slot 122. The slot 122 has an elongated first portion 124 extending from a location adjacent the second end of the arm 120 and a second portion 126 adjacent the first portion 124. The second portion 126 slopes downward and outward from the first portion 124, for example, at an angle of approximately 127 degrees.

[0098] Each arm 120 has a catch 128 formed near a first end thereof. Each catch 128 is configured to engage a corresponding step or lip 130 located on the side of the anvil 104 when the arm 120 is in the first, locked position shown in Figures 12-14. The engagement of the catch 128 with the corresponding lip 130 prevents the cover 108 from moving from the safe position to the retracted position and ensures that the cutting wire 110 is at least partially covered at all times and is not easily accessible by an operator.

[0099] The arms 120 are configured so that, when the pressure bar 102 moves from the retracted position toward the extended (protracted) position, each catch 128 disengages from the corresponding lip 130. In particular, the pressure bar 102 includes two rollers 132 disposed on either side thereof. Each roller 132 is disposed within a slot 122 in the corresponding arm 120. When the pressure bar 102 is in the retracted position shown in FIG. 12 , the roller 132 is located within a first portion 124 of the slot 122. As the pressure bar 102 moves toward the extended (protracted) position, the roller 132 moves within the first portion 124 of the slot 122 relative to the arm 120. As the pressure bar 102 moves further toward the extended position, the roller 132 eventually reaches a second portion 126 of the slot 122, as shown in FIG. 14 . Once the roller 132 enters the second portion 126, the subsequent movement of the pressure bar 102, in combination with the downward tilt of the second portion 126, creates a camming action that causes the arm 120 to pivot clockwise, as shown in Figures 14 and 15. As shown in Figure 15, when the U-shaped member 116 of the pressure bar 102 first contacts the cover 108, the pivoting of the arm 120 lifts the catch 128 from the corresponding lip 130, thereby unlocking the cover 108 and allowing further movement of the pressure bar 102 toward the extended position to move the cover 108 toward the retracted position. At this point, further movement of the pressure bar 102 toward the extended position causes the connected arm 120 to push the cover 108 into the anvil 104 toward the retracted position (see Figure 16).

[0100] In operation, the transport unit 14 dispenses a string of pillows 20 through the exit opening 86 through the rotation of the paddle wheel 62. The length of the string is determined automatically by the control unit 58 or by the amount of time an operator holds down a foot pedal or other actuation means on the apparatus 10. As the pillows 20 exit the transport unit 14, they move downward into an opening 111 defined by the pressure bar 102 and cover 108, which are in their retracted positions, as shown in FIGS. 6 and 12. The angular position of the paddle wheel 62 is indexed to the positions of the pressure bar 102 and cutting wire 110, thereby aligning the particular webbing 24 to be cut with and positioning it therebetween.

[0101] At this point, the control unit 58 activates the actuator 100 of the separating unit 16. The actuator 100 drives the pressure bar 102 toward the webbing 24 (see FIGS. 7, 13, and 14). The U-shaped member 116 of the pressure bar 102 then contacts the webbing 24, and as shown in FIG. 10, the webbing 24 is sandwiched between the U-shaped member 116 and the cover 108. At the point when the U-shaped member 116 tries to push the webbing 24 into the cover 108, the arm 120 has been rotated to the unlocked position by interaction with the roller 132, as shown in FIG. 15.

[0102] As the pressure bar 102 moves further toward the cover 108, the cover 108 is retracted into the anvil 104, as shown in Figures 9 and 16. When the cover 108 is retracted, the cutting wire 110 is no longer present in the channel 113 in the cover 108, and the webbing 24 is pushed toward the cutting wire 110 by the U-shaped member 116 of the pressure bar 102, allowing it to contact the cutting wire 110. As the pressure bar 102 further contacts the cover 108, the webbing 24 is pulled between the protrusions of the U-shaped member 116 and can be stretched toward the cutting wire 110, as shown in Figure 10.

[0103] Contact between the webbing 24 and the cutting wire 110 severs the webbing 24, separating the row of dispensed pillows 20 from the remainder of the chain 22, as shown in Figure 11. At this point, the pressure bar 102 is in the extended (protruding) position and the cover 108 is in the retracted position (see Figures 9 and 16).

[0104] Additionally, during the cutting operation to separate the row of pillows 20 from the remainder of the chain 22, the controller 56 generates an output to rotate the paddle wheel 62 slightly in a direction opposite to the dispensing direction, i.e., the direction opposite to the direction the paddle wheel 62 rotated when dispensing the row of pillows. The reverse rotation of the paddle wheel 62 provides mechanical assistance to separate the row of pillows 20 from the remainder of the chain 22. The reverse rotation also pulls the newly formed tips of the pillow chain 22 back from the contact area of ​​the cutting wire 110, thereby minimizing contact between the pillows 20 and the heated cutting wire 110, thereby preventing the tips from adhering to the cutting wire 110 and causing malfunction of the apparatus 10.

[0105] After being separated from the remainder of the chain 22, the row of pillows 20 is held in place by the U-shaped member 116 of the pressure bar 102 acting on the cover 108. As a result, the row is held suspended from the separation unit 16, as shown in FIG. 11 . An operator or another automated device can easily remove the dispensed row of pillows 20 from the separation unit 16 by pulling on the row. The control unit 58 can instruct the actuator 100 to return the pressure bar 102 to the retracted position at the start of the next dispensing cycle, thereby preparing the separation unit 16 to receive the next row of pillows 20 dispensed from the transport unit 14. More specifically, in this mode of operation, an operator or other automated device can initiate the next or subsequent cycle of dispensing a row of pillows 20 by retracting the actuator 100 before the start of the dispensing process. As described above, the next cycle may be initiated by an operator input to the control unit 58 via an input device such as a foot pedal, push button, or the like. The next cycle may be initiated by a signal sent to the device 10 from another automated device, or may be initiated by another form of input to the device 10.

[0106] Alternatively, the operator may select an operating mode in which the control unit 58 controls the actuator 100 to retract the pressure bar 102 immediately after cutting the webbing 24. In such a mode, the row of pillows 20 falls freely from the separation unit 16.

Claims

1. 1. An apparatus for dispensing pillows for product packaging, comprising: Each cushioning pillow includes a first portion and a second portion having a thickness smaller than that of the first portion; the second portions of adjacent pillows are connected to one another to form a continuous web of pillows; the web defines peaks corresponding to locations of maximum thickness of the first portion and valleys located between the peaks; The device comprises: a conveying unit including at least one pressing member; the pressing member is configured to engage the web of pillows to draw the web of pillows into a transport unit and move the web through the transport unit toward an exit opening of the transport unit; The pressing member is disposed at an angle so as to deviate from the rotation direction of the pressing member.

2. The pressing member includes a vane.

10. The apparatus of claim 1.

3. further comprising a plurality of pressing members; 10. The apparatus of claim 1.

4. the transport unit further includes a hub; The pressing member is attached to the hub, the pressing member extends substantially tangentially to the outer surface of the hub; 10. The apparatus of claim 1.

5. the transport unit further including a guide configured to guide the web of pillows along a path; 10. The apparatus of claim 1.

6. a front side of the pressing member configured to contact and advance the pillows; the front side of the pressing member is inclined at a first angle relative to an adjacent portion of the guide; a rear side of the pressing member is inclined at a second angle relative to an adjacent portion of the guide, the second angle being a supplement to the first angle; the first angle is less than the second angle; 6. The apparatus of claim 5.

7. The guide is a curved portion configured to guide the web of pillow along a curved path; a vertical portion contiguous with the curved portion and configured to guide the web of the pillow toward the exit opening.

6. The apparatus of claim 5.

8. When the pressing member moves through the guide, The guide interferes with the pressing member.

6. The apparatus of claim 5.

9. The pressing member is configured to bend in response to interference between the pressing member and the guide.

9. The apparatus of claim 8.

10. the pressing member and the guide are configured such that when the pressing member moves through the guide, the second portion of the pillow is caught between the tip of the pressing member and the guide.

10. The apparatus of claim 9.

11. The distance between the tips of adjacent pressing members is approximately equal to the length of the pillow.

4. The apparatus of claim 3.

12. the guide is a second guide, the dispensing unit further comprises a first guide; the first and second guides are configured to guide the web of the pillow toward the pressing member; the first and second guides are spaced apart to ensure that the web of pillows is properly engaged within the transport unit; the second guide is configured as a ramp that lifts the web of pillows as it guides the web of pillows along a path.

6. The apparatus of claim 5.

13. the pushing member is configured to advance the web of pillows in a first direction; the dispensing unit further comprising an anti-backup mechanism configured to prevent movement of the web of pillows in a second direction opposite the first direction.

10. The apparatus of claim 1.

14. the anti-return mechanism includes a brush; 14. The apparatus of claim 13.

15. the dispensing unit further comprises a wiper configured to contact the pillow and separate the pillow from the pressing member when the pressing member and the pillow rotate past the wiper.

10. The apparatus of claim 1.

16. The wiper includes a brush.

16. The apparatus of claim 15.

17. More storage bins included. the pressing member is configured to engage the web of pillows as it rotates, the pressing member pulling the web of pillows from the storage bin into the transport unit; 10. The apparatus of claim 1.

18. the transport unit is configured as a modular unit that is mounted on and removed from the storage bin; 20. The apparatus of claim 18.

19. the storage bin including a door configured to provide access to an interior space of the storage bin and a transport unit; 18. The apparatus of claim 17.

20. the pillow is an inflatable pillow; 10. The apparatus of claim 1.

21. One or more pillows are not properly inflated, 21. The apparatus of claim 20.

22. the transport unit is configured to simultaneously engage two or more pillows; 10. The apparatus of claim 1.

23. the transport unit is configured to dispense a predetermined number of pillows; 10. The apparatus of claim 1.

24. the pressing member is configured to prevent damage to the web of pillows while drawing the web of pillows into and passing through the transport unit.

10. The apparatus of claim 1.

25. 1. An apparatus for dispensing pillows for product packaging, comprising: Each cushion pillow is a first portion; and a plurality of second portions having a thickness less than a thickness of the first portions; the second portions of adjacent pillows are interconnected to form a continuous web of pillows, the web defining peaks corresponding to the locations of maximum thickness of the first portions and valleys located between the peaks; the apparatus includes a separation unit configured to receive the web of packaging articles; The separation unit comprises: Anvil and a cover attached to the anvil and configured to be movable relative to the anvil between a first position and a second position of the cover; a press movable between a first position and a second position of the press; a cutting device attached to the anvil and configured to cut the second portion of the pillow upon contact with the second portion; the cover is configured to at least partially cover the cutting device when the cover is in a first position; the press is configured to move the cover from its first position to its second position and to push the web into the cutting device when the press moves from its first position to its second position; The press is configured to at least partially cover the cutting device when the cover is in the cover's second position.

26. the cutting device includes a cutting wire; 26. The apparatus of claim 25.

27. a control element connected to the cover and configured to be pivotable relative to the cover between a first position and a second position of the control element; the control element is configured to engage the anvil when the control element is in the control element first position; Engagement of the control element with the anvil prevents movement of the cover from its first position to its second position.

26. The apparatus of claim 25.

28. the control element includes a locking arm with a latch configured to engage the anvil when the control element is in its first position; 27. The apparatus of claim 26.

29. the press includes a roller; the locking arm has a slot formed therein configured to receive the roller; the rollers move within slots as the press moves from a first position to a second position of the press; the slot is configured to pivot the control element between a first position and a second position by movement of a roller within the slot; 29. The apparatus of claim 28.

30. the slot includes a first portion extending in a first direction and a second portion extending in a second direction different from the first direction; the slot is further configured such that movement of the roller within the second portion of the slot transitions the control element from its first position to its second position.

30. The apparatus of claim 29.

31. When the cover is in the second cover position, the cover does not cover the cutting device.

26. The apparatus of claim 25.

32. the cover defines a channel configured to receive the cutting device when the cover is in a first position; 26. The apparatus of claim 25.

33. the press includes a body and a U-shaped member attached to the body opposite the cutting device and the cover; the U-shaped member is configured to contact edges of the cover at positions above and below the channel when the press moves from the first position to the second position of the press.

33. The apparatus of claim 32.

34. the U-shaped member is configured to stretch the second portion of the pillow between protrusions of the U-shaped member when the press moves from the first position to the second position of the press.

34. The apparatus of claim 33.

35. The U-shaped member is further configured to at least partially cover the cutting device when the cover is in the second position of the cover.

35. The apparatus of claim 34.

36. the U-shaped member and the cover are further configured to contact and clamp the second portion of the pillow above and below the channel.

35. The apparatus of claim 34.

37. the separation unit further includes an actuator configured to move the press between a first position and a second position of the press.

26. The apparatus of claim 25.

38. a conveying unit including a pressing member; a motor configured to move the pressing member during operation; the pressing member is configured to engage the web of pillows to draw the web of pillows into the conveying unit, moving the web of packaging articles along a path within the conveying unit and out an exit opening of the conveying unit; the pressure bar and the cover define an opening configured to receive the web of pillows when the press is in a first position of the press; the opening defined by the press and the cover is located directly below the outlet opening of the transport unit; 38. The apparatus of claim 37.

39. the apparatus further comprising a control unit communicatively connected to the motor; the control unit and the motor are configured to position the pressing member at a plurality of predetermined positions where one of the second portions of the pillow is aligned with the press and the cutting device; 39. The apparatus of claim 38.

40. the transport unit further includes a hub, a plurality of pressing members attached to the hub, a plurality of magnets attached to the hub, and a sensor; the sensors and the magnets are configured such that the sensors are aligned with the respective magnets when the pressing member is disposed at a predetermined angular position; the sensor is configured to generate an output indication when the sensor is aligned with either magnet; the control unit and the motor are configured to position the pressing member so that one of the magnets is aligned with the sensor.

40. The apparatus of claim 39.

41. the control unit and the motor are configured to reverse the direction of rotation of the hub when or after the webbing of the inflated pillow web is cut by the cutting device.

41. The apparatus of claim 40.

42. the control unit and the motor are configured to reverse the rotation direction of the hub when or after the webbing of the packaging article web is cut by the cutting device to minimize contact between the leading edge of the packaging article web and the cutting device.

42. The apparatus of claim 41.

43. 1. An apparatus for dispensing pillows for product packaging, each cushion pillow including a first portion and a second portion having a thickness less than a thickness of the first portion, the second portions of adjacent pillows adjoining one another to form a continuous web of pillows, the web defining peaks corresponding to locations of maximum thickness of the first portions and valleys located between the peaks; The device comprises: a storage bin defining an interior space configured to receive the web of pillows; a duct defining a channel configured to receive the web of pillows and guide the web of pillows in a first direction into the interior space of the storage bin; an air circulation device fluidly connected to the channel and configured, during operation, to force air into the channel at a pressure and flow rate sufficient to move the web of packaging articles into the channel along the first direction; an anti-backup mechanism mounted within the channel and configured to prevent movement of the web of pillow in a second direction opposite the first direction.

44. a conveying unit having a pressing member; the pressing member is configured to engage the web of pillows to draw the web of pillows from the storage bin into the transport unit and to advance the web of packaging articles within the transport unit toward an exit of the transport unit.

44. The apparatus of claim 43.

45. the duct is attached to an outer surface of the storage bin; the duct and an outer surface of the storage bin define the channel; 44. The apparatus of claim 43.

46. the anti-return mechanism includes a tab; 46. ​​The apparatus of claim 45.

47. The interior space of the storage bin has a width approximately equal to the maximum width of the packaging article.

44. The apparatus of claim 43.

48. the storage bin includes first and second side walls spaced apart by a distance defining a width of an interior space of the storage bin; the pillows in the storage bin are restrained from substantial movement in a width direction of the pillows by the first and second side walls; 44. The apparatus of claim 43.

49. the channel has a width approximately equal to the maximum width of the pillow; 44. The apparatus of claim 43.

50. The channels are disposed substantially vertically.

44. The apparatus of claim 43.

51. The channel has a cross-sectional dimension approximately equal to the thickness and maximum width of the packaging article.

44. The apparatus of claim 43.

52. The air circulation device is either a fan or a blower.

44. The apparatus of claim 43.

53. the storage bin is configured such that after the web of pillows enters the storage bin, they fall toward the bottom of the storage bin and fold over on themselves.

44. The apparatus of claim 43.

54. The storage bin is further configured to fold the web of pillows in a random pattern after entering the storage bin.

54. The apparatus of claim 53.

55. the packaging article is an inflatable pillow; 44. The apparatus of claim 43.

56. further comprising an inflation and sealing device; the inflation and sealing device is positioned relative to the storage bin so that the web of pillows is discharged below the bottom of the storage bin; the inflation and sealing device is configured to form a web of inflatable pillows and dispense the web into the storage bin; 56. The apparatus of claim 55.

57. further comprising a conveyor positioned below the bottom of the storage bin; 44. The apparatus of claim 43.

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